Lightweight high-speed relay



June 7, 1966 E. WOOD, JR 3,

LIGHTWEIGHT HIGH-SPEED RELAY Filed May 9, 1963 3 Sheets-Sheet z 17 1J9 INVENTOR 1/6 Aer/we E M600 Je.

United States Patent 3,255,327 LIGHTWEIGHT HIGH-SPEED RELAY Arthur E. Wood, Jr., San Pedro, Calif., assignor to Teledyne Precision, Inc., Hawthorne, Calif., a corporation of Delaware Filed May 9, 1963, Ser. No. 279,056 20 Claims. (Cl. 200-87) In general, the present invention relates to a light compact relay. More specifically, the present invention relates to a relay having a high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance.

Although electrical relays have been known for many years, the demands of modern technology, such as space exploration, have far exceeded the capabilities of the usual relay. For example, the common relay is relatively bulky and heavy. Also, the usual relay weighs at least several ounces and occupies'at least several cubic inches of space. tively large, rotating mechanical components and, consequently, short life. Also, the usual relay is particularly susceptible to vibrations and shocks. In addition, during their switching operation, the usual relay requires relatively high power and exhibits substantial contact- Still another object of the present invention is a relayhaving low power consumption during its switching operation and low contact resistance.

Other objects and advantages of the present invention will be readily apparent from the following description and drawings which illustrate a preferred exemplary embodiment of the present invention.

In general, the relay of the present invention comprises a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon. Joined to the first current pin lead end is a first stationary contact which extends towards the second current pin lead end. Also a second stationary contact is joined to the second current pin lead end and extends toward the first current pin lead end. The free ends of said stationary contacts are overlapped and spaced apart. Also mounted on the support header is at least one moving contact which is electrically connected to the third current pin. The moving contact has a free end extending between the free ends of the stationary contacts. A coil is electrically connected to the coil pins. Supporting such coil adjacent the moving contact is a frame which includes leg means for mounting on the support header and a first magnetic pole. Extending through said coil is a magnetic core which is joined at its first end to the frame and forms a second magnetic .pole 'at its second end spaced from the first magnetic pole. The frame and core form a magnetic circuit when the coil is energized. Pivotally connected to the core between the coil and the moving contact is an armature adapted by movement to an extended position to operate the moving contact when said In addition, the usual relay has relacoil is energized and to substantially balance about its pivot connection. Finally, mounted on the support header is a return spring which is adapted to separate the armature from the moving contact by moving it to a retracted position when the coil is de-energized. Also said return spring is adapted to hold the armature against a stop in such retracted position without vibration.

In order to facilitate understanding of the present invention, reference will now be made to the appended drawings of a preferred specific embodiment of the present invention. Such drawings should not be construed as limiting the invention which is set forth in the appended claims. In the drawings:

FIGURE 1 is an axial cross-sectional view of a preferred embodiment of the relay of the present invention showing the armature in its retracted position.

FIGURE 2 is a cross-sectional view of FIGURE 1 taken along the lines 22 of FIGURE 1.

FIGURE 3 is a cross-sectional view of FIGURE 1 along the lines 3-3 of FIGURE 1.

FIGURE 4 is an exploded perspective view of the cover and magnetic circuit assembly portion of the relay of FIGURE 1.

FIGURE 5 is an exploded perspective view of the header assembly portion of the relay of FIGURE 1.

FIGURE 6 is a view similar to FIGURE 1 wherein the armature is in its extended position.

FIGURE 7 is a cross-sectional view of FIGURE 6 taken along the lines 77 of FIGURE 6.

FIGURE 8 is a cross-sectional view of the core and armature assembly of the present invention illustrating the method of joining them together.

FIGURE 9 is an axial cross-section of another embodiment of the relay of the present invention.

FIGURE 10 is a plan view of still another embodiment of the present invention with the cover removed.

FIGURE 11 is a cross-sectional view of FIGURE 10 taken along the lines 1111 of FIGURE 10 showing the armature in its extended position.

FIGURE 12 is a cross-sectional view of FIGURE 10 taken along the lines 1212 of FIGURE 10.

In general, as illustrated in FIGS. 1-8, the relay 10 of the present invention includes a cover 11, a header assembly 15 and a magnetic circuit assembly 40.

The header assembly 15 includes a support header 16 which is formed out of a circular disk 17, having a central circular platform 18. The platform 18 forms a shelf 19 around the periphery of the disk 17. On the shelf 19 is a circumferential bead 20 (FIG. 5) adapted to facilitate welding of the cover 11 to the support header 16. The platform 18 has sockets 21 which are' adapted to receive thelegs 46 of the frame 45. The

cover 11 is adapted to be slidingly received onto the platform 18 and has a flange 12 which fits in mating relationship with the shelf 19. The cover 11 is hermetically sealed to the support header 16 and encloses the remainder of the relay. Preferably such hermetic seal is achieved by welding the flange 12 to the shelf 19 during which process the head 20 is flattened out as illustrated in FIGS. 1 and 6.

Mounted on the support header 16 are at least three current pins, i.e., a first, a second and a third current pin, 25, 26 and 27 respectively. At least two of such current pins, i.e., the first and second current pins, and 26, have their lead ends, 25' and 26' respectively, projecting above the surface 22 of the header 16. A first stationary contact 28 is joined to the first current pin lead end 25, and extends adjacent the second current pin lead end 26. A second stationary contact 29 is joined to the second current pin lead'end 26 and extends adjacent the first current pin lead end 25'. The free ends of the contacts 28 and 29 are overlapped and spaced apart. As illustrated, each of the stationary contacts 28 and 29 comprises an arcuate wire having substantially the same radius and center of curvature. At least one moving contact 30 is mounted on the support header 16 and is electrically connected to the third current pin 27. The moving contact 30 has a free end 31 extending between the free ends of the stationary contacts 28 and'29. As illustrated in FIGS. 1 and 6, particularly, the moving contact 30 is electrically connected to the third current pin 27 by mounting it directly on the support header 16 and joining the third current pin 27 directly to the support header 16. Since support header 16 is formed out of an electrically-conductive material, such arrangement completes the circuit between the moving spring 30 and third current pin 27. As illustrated in FIG. 1, the moving contact 30 is biased into engagement with the first stationary contact 28 which is adjacent to the coil 41 when the armature 65 is in its retracted position.

Finally, the header assembly includes a return spring 35 mounted on the support header 16 and adapted to separate the armature 65 from the moving contact by moving the armature 65 into a retracted position when the coil 41 is de-energized. In addition, the return spring is adapted to hold the armature 65 in such position without vibration. Also mounted on the support header 16 is a stop 36 which is adapted to brace the armature 65 in its retracted position. The support header 16 also has at least two coil pins 37 and 38 which have their lead ends 37 and 38, respectively, projecting above the surface 22 of the header.

The magnetic circuit assembly 40 includes a coil 41 electrically connected to the coil pins 37 and 38 by wires 42. The current pins 25 and 26 and the coil pins 37 and 38 are hermetically sealed to the support header 16 by means of fused glass seals 39 while the thirdcurrent pin may be butt welded directly to the support header 16. Supporting the coil 41, adjacent to the moving'contact 30, is a frame 45 which includes leg means by which it is mounted on the support header 16. As illustrated, leg means comprises two legs 46 with each of the legs 46 being received in a socket 21 in the platform 18 of the support header 16. The frame 45 has a third leg 47 which partially encloses the coil 41 and has an arcuate end 48 partially surrounding a core 55 so that the third leg 47 forms the first magnetic pole of the magnetic circuit assembly. Separating each side of the coil 41 from the frame 45 are split washers 49 having slots 50 therein which minimize induced currents in the washers 49 which would delay the operation of the relay 10.

Extending through the central aperture 51 of the coil 41 is a magnetic core 55 which is joined to the frame 45 at its first end 56 and forms a second magnetic pole at its second end 57 spaced from the first magnetic pole. The frame 45 and the core 55 form a magnetic circuit when the coil 41 is energized. As illustrated, core 55 includes a yoke 58 at its second end 57 with the yoke 58 including a crossbar 59 which clamps the coil 41 to the frame 45. Crossbar 59 has an arcuate central portion 60. arcuate leg end 48 of the frame 45 and the arcuate central portion 60 of the core crossbar 59 have substantially the same center of curvature.

Pivotally connected to the yoke 58 of the core 55 between the coil 41 and the moving contact 30 is an armature which is adapted by movement to an extended position (FIG. 6) to operate the moving contact 30 when the coil 41 is energized. Also, the armature 65 is substantially balanced about the pivot connection 66. The pivot connection 66 is formed by an armature clip 67 which is formed initially out of a single piece of metal, then welded to the legs 61 of the yoke 58 and finally the central portion 67' (shown dotted in FIG. 8) is removed. By such method of joining the armature clip 67 to the core 55, a fast, accurate assembly is achieved. The armature 65 comprises a fiat piece of metal 68 which is thicker and tapered at its first end 69 with a finger 70 extending The towards the moving contact 30. Finger 70 is adapted to strike the moving contact 30 adjacent to its free end 31. The armature 65 is pivotally joined to the yoke 58 in its central portion 71 by means of recesses 72. At its second end 73, the armature 65 is positioned and curved to substantially conform to the configuration of the coil 41. Across the first end 69 of the armature 65 is a groove 74 which is adapted to facilitate the adjustment of the finger 70 with reference to the moving contact 30. Also, the armature 65 has notches 75 formed in its side adjacent its second end 73 which are sufficient to substantially balance the armature 65 about its pivot edge 76 but insufficient to substantially impair the magnetic circuit.

During the operation of the relay illustrated in FIGS. l8, when the coil 41 is de-energized (FIG. 1), the return spring 35 biases the armature 65 into con-tact with the core 55 with the pivot edge 76 by pressing against its first end 69. Concurrently, the second edge end 73 of the armature 65 is braced against the stop 36. With the armature 65 in such retracted position, the moving contact 30 is biased against the first stationary contact 28 at its free end 31. When the coil 41 is energized,.the armature 65 is attracted to and'rests with its second end '73 in contact with the first and second magnetic poles (FIG. 6). Such movement of the armature '65 moves its finger 7 0 downward to force the free end 31 of the moving contact 30 into contact with the second stationary contact 29. When the coil 41 is again de-energized, the armature is returned to its initial position by the return spring 35, and the moving contact 30 returns to its initial position by the bias therein.

The following specific example will serve to illustrate the invention and to make clear the manner in which it may be practiced. Such example should not be construed as limiting the invention which is set forth in the appended claims.

A. relay was constructed as illustrated in FIGS. 18 wherein the height of the assembled relay without including the pins was a maximum of 0.260 inch, and the maximum diameter was 0.370 inch. Thus the total volume of the relay was less than approximately 0.08 cubic inch. In addition, the final weight of the complete assembly was about 0.08 ounce. The construction was all welded and utilized glass to metal seals. The resulting relay is adapted to actuate in a range of about nine to sixteen vol-ts under direct current in a temperature range from minus 65 C. to plus C. The contact resistance was found to be less than 0.2 ohm maximum and an average about 0.1 ohm. Upon testing, it was found the relay could operate without failure at 28 UDC contact loads as follows: at .001 amp, up to 40,000,000 operation, at 0.5 amp, up to 5,000,000 operation and at one amp. over 100,000 operation. When tested for resistance for vibration, it was subjected to acceleration of 30 GS (1 G being the acceleration due to gravity) and 3,000 cycles per second and no contact chatter was observed. Also when tested for operation under shock conditions, it was subjected to a series of shocks of 100 GS magnitude and all of 11 milliseconds duration, and no contact chatter was observed. To energize, the operation time and transfer time was a maximum of 1.5 milliseconds while to de-energize, the operation time'and transfer time was a maximum of 1.5 milliseconds. It required only 0.013 amp. at 26 volts to energize the coil, and when energized at this level there was no apparent contact bounce.

Another embodiment of the present invention is illustrated in FIG. 9 where the third current pin 127 has its lead end 127' projecting above the surface 122 of the support header 116. In such arrangement, the third current pin 127 is insulated from the support header 116 and from the return spring by a glass seal 139 and a Teflon gasket 180. With such arrangement, the moving contact 130 is joined directly to the third current pin lead end 127. As illustrated in FIG. 9, the remaining portions of this embodiment are substantially the same as shown in FIGS. 1-8.

In FIGS -12, still another embodiment of the present invention is illustrated involving a double pole, double throw relay. As shown, header assembly 215 includes a support header 216 which is formed of a circular disc 217 having a central circular platform 218. The platform 218 forms a shelf 219 around the periphery of the disc 217. On the shelf 219 is a circumferential bead 220 adapted to facilitate welding of the cover (not shown) to the support header 216. The platform 218 has sockets 221 which are adapted to receive the legs (not shown) of the frame (not shown). The cover and magnetic circuit assembly portions of the embodiment illustrated in FIGS. 10-12 is substantially the same as that illustrated in FIGS. 1-8.

Mounted on the support header 216 are six current pins, i.e., a first, a second, a third, a fourth, a fifth and a sixth current pin, 22 5, 226, 227, 228, 229 and 230 respectively. At least four of such said current pins i.e., the first, second, third and fourth current pins, 225, 226, 227 and 228 respectively, have their lead ends 225, 226', 22 7 and 228 respectively, projecting above the surface 222 of the header 216. A first stationary contact 240 is joined to the first current pin lead in 225 and extends adjacent the second current pin lead in 226'. stationary contact 241 is joined to the second current pin lead in 226 and extends adjacent the first current pin lead in 225'. A third stationary contact 242 is joined to the third current pin lead in 227' and extends adjacent the fourth current pin lead in 228'. A fourth stationary,contact 243 is joined to the fourth current pin lead in 228' and extends adjacent the third current pin lead in 227. The ends of the first and second contacts 240 and 24 1 respectively and the ends of the third and fourth contacts 242 and 243 respectively are overlapped and spaced apart. As illustrated, each of the stationary contacts 240, 241, 242 and 243 comprises an arcuate wire having substantially the same radius and center of curvature.

A first mowing contact 245 is mounted on the support header 216 and electrically connected to the fifth current pin .229 by being directly mounted on the projecting lead in 229' of the current pin '229 which is mounted on the support header 216. The first moving contact 45 has a free end 246 which extends between the free ends of the third and fourth stationary contacts 242 and 243. A second moving contact 247 is mounted on the support header 216 and electrically connected to the sixth current 7 pin 230 by being mounted directly on the projecting lead in 230' of the current pin 230 which is mounted on the support header 216. The second moving contact 247 has a free end 248 extending between the free ends of the first and second stationary contacts 240 and 241. The moving contacts 245 and 247 are biased into engagement with the second and third stationary contacts 241 and 242 respectively which are adjacent to the coil 250 when the armature 251 is in its retracted position.

The header assembly 215 includes a return spring 252 mounted on the support header 2 16 and adapted to separate the armature 251 from the moving contacts 245 and 247 by moving the armature 251 into a retracted position when the coil F250 is de-energized. In addition, the return spring 252 is adapted to hold the armature 251 in such position without vibration. Also mounted on the support header 216 is a stop 253 which is adapted to brace the armature 25.1 in its retracted position. The support header 216 also has two coil pins 255 and 256 which have their lead ins 255 and 256, respectively, projecting above the surface 222 of the header 216 and are electrically connected to the coil 250 by wires 257.

' In general, the magnetic circuit assembly (partially shown) is substantially similar to the magnetic circuit assembly of FIGS. 1-8. The current pins 225, 226,

A second 227, 228, 229 and 230 and the coil pins 255 and 256 are hermetically sealed to the support header 216 by means of fused glass seals 258. As illustrated, the third leg 260 which partially encloses the coil 250 has an arcuate end 261 partially surrounding the core 262 to iform the first magnetic pole of the magnetic assembly. Separating each side of the coil 250 from the frame are split washers 263. The core 262 has a crossbar (not shown) with an arcuate central portion 263. Similarly, the armature 251 has a finger .264 adapted to strike the moving contacts 245 and 247 adjacent their free ends 246 and 248 respectively. In addition, there is a gasket 265 which insulates the fifth and sixth current pins 229 and 230 from the support header 216.

Many other specific embodiments of the present invention will be obvious to one skilled in the art in view of this disclosure. For example, note FIGS. 9-12. Other embodiments of the present invention may utilize variation such as mounting the moving contact on a coil terminal.

There are manyfeatures in the present invention which clearly show the significant advance the present invention represents over the prior art. Consequently, only a few of the more outstanding features will be pointed out to illustrate the unexpected and unusual results attained by the present invention. One feature of the present invention is its outstanding advantages of compactness (total volume less than 0.08 cubic inch) and light weight (total weight about 0.08 ounce). Another feature of the present invention is the utilization of a one-piece frame in the magnetic circuit to support the coil and form one pole. Such arrangement achieves both an eflicient magnetic circuit and a rugged construction. Still another feature of the present invention involves the armature wherein its configuration is adjusted to provide suificient magnetic flux while achieving a balance about its fulcrum. By bracing the first end of the armature with a return spring, and the second end of the armature with a stop with the fulcrum in the center coupled with the overall balance of the armature, a very stable construction resistant to vibration and shock is produced. In addition, the armature includes a groove which facilitates its adjustment. Also, by mounting the contacts, both stationary and movingydirectly on the support header and utilizing arcuate wires for the stationary contacts, a simple rugged and inexpensive construction is achieved.

It will be understood that the vforegoing description andexamples are only illustrative of the present invention and it is not intended that the invention be limited thereto. All substitutions, alterations and modifications of the present invention which come within the scope of the following claims, or to which the present invention is readily susceptible without departing from the spirit and scope of this disclosure are considered part of the present invention.

'1 claim:

1. A light, comp-act, relay having high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance comprising:

'(a) a support header having at least three current' pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon;

'(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overlapped and spaced apart;

(c) at least one moving contact mounted on said support header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a coil electrically connected to said coil pins;

(e) a magnetic frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said core between said coil and moving contact, said armature being adapted by movement to an extended position to operate said moving contact when said coil is energized and to substantially balance above said pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to a retracted position when said coil is de-energized and to hold said arnratu-re in said retracted position without vibration.

2 A relay as stated in claim 1 which includes a cover hermetically sealed to said support header and enclosing the remainder of said relay.

3. A relay as stated in claim 1 which includes a stop mounted on said support header and adapted to brace said armature in said retracted position.

4. A relay as stated in claim 1 wherein said support header comprises a circular disk with a central circular platform.

5. A relay as stated in claim 1 wherein said third current pin is joined directly to said support header and said moving contact is mounted directly on said support header.

6. A relay as stated in claim 1 wherein said third current pin has its lead end projecting above the surface of said header and said moving contact is joined to said third current pin lead end.

7. A relay as stated in claim 1 wherein said coil pins have their lead ends projecting above the surface of said header. 7

8. A relay as stated in claim- 1 wherein each of said stationary contacts comprises an arcuate wire having substantially the same radius and center of curvature.

9. A relay as stated in claim 1 wherein said moving contact is biased into engagement with the first stationary contact and said contact is adjacent to said coil.

It). A relay as stated in claim 1 wherein said frame has at least two legs with each of said legs being received in sockets in said support header.

11. A light, compact, relay having high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance comprising:

(a) a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon;

(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overlapped and spaced apart;

() at least one moving contact mounted on said sup port header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a coil electrically connected to said coil pins;

(e) a frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said core between said coil and moving contact, said armature being adapted by movement to an extended position to operate said moving contact when said coil is energized and to substantially balance above said pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to aretracted position when said coil is de-energized and to hold said armature in said retracted position without vibration;

(i) said frame having a third leg partially enclosing said coil and having an arcuate end partially surrounding said core, said third leg forming said first magnetic pole.

12. A light, compact, relay having high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance comprising:

(a) a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of saidheader and at least two coil pins mounted thereon;

(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overlapped and spaced apart;

(c) at least one moving contact mounted on said support header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a coil electrically connected-to said coil pins;

(e) a frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said core between said coil and moving contact, said armature being adapted 'by movement to an extended position to operate said moving contact when said coil is energized and to substantially balance above said pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to a retracted position when said coil is de-energized and to hold said armature in said retracted position without vibration;

(i) said core including a yoke at its second end, said I yoke comprising a cross-bar which clamps said coil to said frame and which has an arcuate central portion, the arcuate leg end of said frame and the arcuate central portion of said core cross-bar having substantially the same center of curvature.

13. A light, compact, relay having high reliability overv a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance comprising:

(a) a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil .pins mounted thereon;

(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overlapped and spaced apart;

(c) at least one moving contact mounted on said sup port header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a coil electrically connected to said coil pins;

(e) a frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said corebetween said coil and moving contact, said armature being adapted by movement to an extended position to operate said moving contact when said coil is energized and to substantially balance abovesaid pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to a retracted position when said coil is de-energized and to hold said armature in said retracted position without vibration;

(i) an armature clip joined to said core, said armature clip pivotally connecting said armature to said core.

14. A light, compact, relay having high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low

power consumption during its switching operation and low contact resistance comprising: i

(a) a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon;

(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overtapped and spaced apart;

(c) at least one moving contact mounted on said support header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said core between said coil and-moving contact, said armature being adapted by movement to an extended position to operate said moving contact when said coil is energized' and to substantially balance above said pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to a retracted position when said coil is de-energized and to hold said armature in said retracted position without vibration;

(i) said armature comprising a substantially flat piece of metal tapered at its first end with a finger extending toward said moving contact, said finger being adapted to strike said moving contact adjacent its free end; pivotally joined to said core in its central portion end, positioned-and curved at its second end to substantially conform to said coil configuration.

15. A relay as in claim 14 wherein said armature has a groove across its first end adapted to facilitate the adjustment of its finger position with reference to the moving contact.

16. A relay as in claim 14 wherein said armature has notches formed in its side adjacent its second end sufficient to substantially balance the armature about its pivot, but insutficient to substantially impair the magnetic circuit.

17. A light, compact, relay having high reliability over a large number of switching operations, substantially no contact bounce under severe vibrations and shocks, low power consumption during its switching operation and low contact resistance comprising:

(a) a support header having at least three current pins mounted thereon with at least two of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon;

(b) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end and a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, the ends of said contacts being overlapped and spaced apart;

(c) at least one moving contact mounted on said support header and electrically connected to the third current pin, said moving contact having its free end extending between the free ends of said stationary contacts;

(d) a coil electrically connected to said coil pins;

(e) a frame supporting said coil adjacent said moving contact, said frame including a first magnetic pole and leg means by which it is mounted on said support header;

(f) a magnetic core extending through said coil, said core being joined to said frame at its first end and forming a second magnetic pole at its second end spaced from said first magnetic pole, said frame and core forming a magnetic circuit when said coil is energized;

(g) an armature pivotally connected to said core between said coil and moving contact, said armature being adapted by movement to an extended position to operate said moving contact when said coil is energized and to substantially balance above said pivot connection;

(h) a return spring mounted on said support header and adapted to separate said armature from said moving contact by moving said armature to a retractcd position when said coil is de-energized and to hold said armature in said retracted'position without Vibration;

(i) six current pins with at least four of said current pins having their lead ends projecting above the surface of said header and at least two coil pins mounted thereon;

(j) a first stationary contact joined to the first current pin lead end and extending adjacent the second current pin lead end, a second stationary contact joined to the second current pin lead end and extending adjacent the first current pin lead end, a third stationary contact joined to the third current pin lead end and extending adjacent the fourth current pin lead end, and a fourth stationary contact joined to the fourth current pin lead end and extending adjacent the third current pin.lead end, the ends of said first and second contacts and third and fourth contacts being overlapped and spaced apart;

(k) first and second moving contacts mounted on said support header and electrically connected to the fifth and sixth current pins, respectively, the first moving contact having its free end extending between the free ends of said third and fourth stationary contacts and the second moving contact having its free end extending between the free ends of said first and second stationary contacts.

13. A relay as in claim 17 wherein each of said stationary contacts comprises an'arcuate wire having substantially the said radius and center of curvature.

19. A relay comprising a support header having contact pins extending therethrough, fixed contact members carried by at least twoof said contact pins on one 12' side of said header, an electromagnet having a frame supporting the same spaced from said one side of said header, said frame defining a fiux path for said electromagnet and including a core portion extending therethrough, an armature pivotally mounted on said core portion between said electromagnet and said header, a movable contact carried by said header, electrically connected to another of said pins and having a contact portion movable between said fixed contact members, said movable contact being normally in engagement with one of said fixed contacts and being in the path of pivotal movement of one portion of said armature, means separate from said movable contact biasing said armature to move its said portion away from said movable con- 15 tact, said armature being arranged relative to said electromagnet so that its said one portion is swung to said movable contact and moves the same to the other fixed contact when said electromagnet is energized.

20. A relay as defined in claim 19 wherein said sup- 20 port header is electrically conductive, said at least two contact pins being electrically insulated therefrom, said movable contact and said member of said pins being electrically connected to said header.

References Cited by the Examiner UNITED STATES PATENTS 2,955,174 10/1960 Richert 20087 2,960,583 11/1960 Fisher et al. 200-87 3,033,957 5/1962 Dean 20087 3,042,775 7/1962 Jordan 317 197 3,048,749 8/1962 Koehler 20087 3,051,804 8/1962 Mayer 20087 3,076,073 1/1963 Townsend 317198 BERNARD A. GILHEANY, Primary Examiner.

ROBERT K. SCHAEFER, Examiner.

B. DOBECK, Assistant Examiner.

Disclaimer 3,255,327.;lrthur E. lVoocl, J71, San Pedro, Calif. LIGHTWEIGHT HIGH- SPEED RELAY. Patent dated June 7 1966. Disclaimer filed Sept. 3, 1970, by the assignee, Teledy'ne, Inc. Hereby enters this disclaimer to claims 19 and 20 of said patent.

[Ofii'cz'al Gazette January 536, 1.971] 

1. A LIGHT, COMPACT, RELAY HAVING HIGH RELIABILITY OVER A LARGE NUMBER OF SWITCHING OPERATIONS, SUBSTANTIALLY NO CONTACT BOUNCE UNDER SEVERE VIBRATIONS AND SHOCKS, LOW POWER CONSUMPTION DURING ITS SWITCHING OPERATION AND LOW CONTACT RESISTANCE COMPRISING: (A) A SUPPORT HEADER HAVING AT LEAST THREE CURRENT PINS MOUNTED THEREON WITH AT LEAST TWO OF SAID CURRENT PINS HAVING THEIR LEAD ENDS PROJECTING ABOVE THE SURFACE OF SAID HEADER AND AT LEAST TWO COIL PINS MOUNTED THEREON; (B) A FIRST STATIONARY CONTACT JOINED TO THE FIRST CURRENT PIN LEAD END AND EXTENDING ADJACENT THE SECOND CURRENT PIN LEAD END AND A SECOND STATIONARY CONTACT JOINED TO THE SECOND CURRENT PIN LEAD END AND EXTENDING ADJACENT THE FIRST CURRENT PIN LEAD END, THE ENDS OF SAID CONTACTS BEING OVERLAPPED AND SPACED APART; (C) AT LEAST ONE MOVING CONTACT MOUNTED ON SAID SUPPORT HEADER AND ELECTRICALLY CONNECTED TO THE THIRD CURRENT PIN, SAID MOVING CONTACT HAVING ITS FREE END EXTENDING BETWEEN THE FREE ENDS OF SAID STATIONARY CONTACTS; (D) A COIL ELECTRICALLY CONNECTED TO SAID COIL PINS; (E) A MAGNETIC FRAME SUPPORTING SAID COIL ADJACENT SAID MOVING CONTACT, SAID FRAME INCLUDING A FIRST MAGNETIC POLE AND LEG MEANS BY WHICH IT IS MOUNTED ON SAID SUPPORT HEADER; (F) A MAGNETIC CORE EXTENDING THROUGH SAID COIL, SAID CORE BEING JOINED TO SAID FRAME AT ITS FIRST END AND FORMING A SECOND MAGNETIC POLE AT ITS SECOND END SPACED FROM SAID FIRST MAGNETIC POLE, SAID FRAME AND CORE FORMING A MAGNETIC CIRCUIT WHEN SAID COIL IS ENERGIZED; (G) AN ARMATURE PIVOTALLY CONNECTED TO SAID CORE BETWEEN SAID COIL AND MOVING CONTACT, SAID ARMATURE BEING ADAPTED BY MOVEMENT TO AN EXTENDED POSITION TO OPERATE SAID MOVING CONTACT WHEN SAID COIL IS ENERGIZED AND TO SUBSTANTIALLY BALANCE ABOVE SAID PIVOT CONNECTION; (H) A RETURN SPRING MOUNTED ON SAID SUPPORT HEADER AND ADAPTED TO SEPARATE SAID ARMATURE FROM SAID MOVING CONTACT BY MOVING SAID ARMATURE TO A RETRACTED POSITION WHEN SAID COIL IS DE-ENERGIZED AND TO HOLD SAID ARMATURE IN SAID RETRACTED POSITION WITHOUT VIBRATION. 